Modular top padded mattress

ABSTRACT

A modular mattress having a spring coil assembly with a plurality of springs coils having a spring wrapped in a thin fabric and arranged in a generally rectangular shape, a sturdy fabric exterior surrounding the plurality of spring coils, and a first connection element. The mattress also includes a padding assembly with a polyurethane foam in a generally rectangular shape corresponding to the shape and size of the spring coil assembly, a sturdy fabric exterior surrounding the polyurethane foam, and a second connection element. The first connection element and the second connection element are configured to couple the spring coil assembly and the padding assembly.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims benefit of U.S. Provisional Patent Application No. 62/657,030, filed on Apr. 13, 2018, entitled “MODULAR TOP PADDED MATTRESS,” the disclosure of which is hereby incorporated herein by reference in its entirety.

BACKGROUND OF THE DISCLOSURE

A typical mattress is made up of three main parts: an inner spring section, the padding, and a top quilt. These sections are generally formed separately, and then attached to one another by wrapping each section in a sturdy fabric and sewing together. In this way the mattress is a unitary unit that cannot easily be taken apart and repaired. However, the different pieces of the mattress have vastly different life cycles. For instance, the spring coils may last 20-25 years before needing replacement, while the padding may need to be replaced after 3-10 years.

There is a need for a modular mattress that allows users to easily separate and replace individual portions, saving consumer's money by removing the need to replace the entire mattress and helping the environment by reducing waste generated by replacing entire mattresses every 3-10 years. Additionally, the modular portions of the mattress may more easily be transported separated, as opposed to shipping an entire mattress as a unitary unit.

SUMMARY OF THE PRESENT DISCLOSURE

One aspect of the present disclosure includes a modular mattress having a spring coil assembly with a plurality of spring coils having a spring wrapped in a thin fabric and arranged in a generally rectangular shape, a sturdy fabric exterior surrounding the plurality of spring coils, and a first connection element. The mattress also includes a padding assembly with a polyurethane foam in a generally rectangular shape corresponding to the shape and size of the spring coil assembly, a sturdy fabric exterior surrounding the polyurethane foam, and a second connection element. The first connection element and the second connection element are configured to couple the spring coil assembly and the padding assembly.

Another aspect of the present disclosure includes a modular mattress having a spring coil assembly with a generally rectangular shape and including spring coils surrounded by a fabric exterior and a padding assembly corresponding to the shape and size of the spring coil assembly and including a sturdy fabric exterior surrounding a polyurethane foam. The modular mattress spring coil assembly and the padding assembly are removably coupled together by a first connection element on the spring coil assembly and a second connection element on the padding assembly.

Still another aspect of the disclosure includes a modular mattress having a spring coil assembly with spring coils having a spring wrapped in a thin fabric and arranged in a generally rectangular shape, a first sturdy fabric exterior surrounding spring coils and a first connection element sewn to the first sturdy fabric exterior. The modular mattress also has a padding assembly with a polyurethane foam in a generally rectangular shape corresponding to the shape and size of the spring coil assembly, a second sturdy fabric exterior surrounding the polyurethane foam, and a second connection element sewn to the second sturdy fabric exterior. The first connection element and the second connection element are configured to removably couple the spring coil assembly and the padding assembly.

These and other aspects, objects, and features of the present disclosure will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is an isometric view of an embodiment of a mattress with the connection elements coupled.

FIG. 2 is an isometric view of an embodiment of a mattress with the connection elements uncoupled.

FIG. 3 is a side view of an embodiment of a mattress with the foam section pulled back from the coil spring portion.

FIG. 4 is an isometric view of the coil spring section of the mattress of an embodiment.

FIG. 5 is an enlarged view of the foam section of the mattress of an embodiment rolled over showing both the top side and bottom of the foam section.

FIG. 6 is a cross section view showing the zipper connection between the coil spring portion and the foam section of the mattress of an embodiment.

FIG. 7 is a cross section view showing the zipper connection between the coil spring portion and the foam section of the mattress of an embodiment with an overlay.

FIG. 8 is a cross section view showing the zipper connection between the coil spring portion and the foam section of the mattress of another embodiment with an overlay.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in FIG. 1. However, it is to be understood that the disclosure may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

A modular mattress 10 may have two easily separable pieces. A spring coil section 12 may comprise a matrix of individually wrapped spring coils wrapped in a sturdy fabric, in a generally rectangular shape. The size of the spring coil section depends on the size of mattress being produced, and generally includes 900-2000 coils. The spring coil section 12 forms the base of the modular mattress and provides the base support for the consumer.

On top of the spring coil section 12 is a padding section 14. The padding section 14 is most responsible for the comfort of the mattress to the user. The padding section 14 is generally a polyurethane foam with a density that ranges generally from 1.5-1.8 lb./ft{circumflex over ( )}3, however the foam may be more or less dense depending on the user's preferences. The polyurethane foam is then wrapped in a sturdy fabric into a rectangular shape that matches the spring coil section.

Overlaying both the spring coil section 12 and the padding section 14 is a sturdy fabric like a quilting. The quilting provides a key component of comfort because it gives a mattress its surface comfort. It also serves to secure the outermost fabric to the mattress's interior layers: the layers of foam, and other fill.

In a typical mattress the quilting overlaying the foam is sewn to the quilting overlaying the spring coils, which provides a unitary mattress to a user. Instead, in the disclosure, the two parts 12, 14 are formed and manufactured separately, each with a connecting element 40. The spring coil connecting element 42 may be on the top of the spring coil section 12, and the padding section connecting element 44 may be on the bottom of the padding section 14. The two connecting elements 42, 44 may be brought together to hold the mattress together during use. The connecting elements may then be disengaged to remove one portion or the other for replacement or cleaning.

As shown in FIG. 6, the connecting elements in an embodiment are a zipper 40. The spring coil connecting element 42 may be a first zipper half including a length of zipper teeth of a standard size and configuration. The spring coil zipper half 42 may be on the top surface 13 of the spring coil section 12, inset from the perimeter of the top surface 13 a distance. The length of the zipper is such that the zipper is disposed around the entire perimeter of the mattress. The padding section 14 has a corresponding foam section connecting element 44 which may be a second zipper section with the standard size and configuration of teeth. The size and configuration corresponds with the first zipper section 42 such that the two sections may be connected. The second zipper section 44 is disposed on the bottom portion 15 of the padding section 14, and may be inset from the perimeter of the bottom surface 15 of the padding section 14 by a corresponding distance from the perimeter. This distance may be a standard distance to provide a user with ease of replacement of either section by allowing a new section to be attached, and set such that the zipper is protected from users when the two pieces are connected by the overlay caused by the inset distance of the zipper from the perimeter of the two sections. For reference, the location of the zipper parts in one embodiment are generally shown as 122 and 124 in FIGS. 1-5. FIG. 6 shows a cross-sectional view of the zipper location inset from the perimeter of the mattress 10.

In another embodiment, the connection 40 between the two sections 12, 14 may be connected by a hook and loop connections (such as e.g. Velcro®). In this embodiment, there may be sections of hook and loop connectors around the perimeter of the mattress, on the top surface 13 of the spring coil section 12 and the bottom surface 15 of the padding section 14. The connector sections may again be located in a standard fashion in order to correspond to one another, and be inset from the perimeter of the mattress to avoid snagging by a user.

In another embodiment, single attachments 40 may be used. The single attachments may include toggles (cylinder through a hoop), snaps, or straps and buckles. If single attachments are used they must be spaced appropriately. For most mattress sizes, the single attachments may be placed about 1′ from the corners on each of the head, foot, right, and left sides, with and additional connector in the middle of the left and right sides , as shown in FIG. 1. For a king size mattress, an additional connector may be necessary on the head and foot sides as well. FIGS. 1-5 show how the straps and buckles may be used, but it should be known that a zipper or any other kind of connector may be used.

In still another embodiment as shown in FIGS. 7-8, the quilt portion of the padding section overlays the entire modular mattress. In other words, the padding section 14 is placed on top of the spring coil section 12 as described above. The quilt of the padding section may have an overlay 50 that reaches over the head, foot, right, and left sides of the spring coil section 12. The padding section 14 may be connected in any of the above mentioned manners, but may reach to the bottom surface of the spring coil section 12 (see FIG. 7). In this manner, a user need not find a matching fabric of the padding section when it is being replaced, but can present a new and updated outer surface of the mattress each time the padding section 14 is replaced.

Looking at FIG. 7, this overlay 50 may be attached to the bottom surface of the spring coil section 12 at a distance inset from the perimeter of the bottom surface as described above. The connector may also be attached along the sides of the spring coil section near the bottom. The overlay may also cover the zipper by approximately 1″, offering cover for the zipper to prevent damage to the zipper or to prevent a user from snagging on the zipper. Covering the zipper, which includes some amount of material that the teeth of the zipper connect to, may also help in the fire resistance of the mattress, by covering the zipper material with the fire retardant quilting material.

In another embodiment as shown in FIG. 8, an overlay 50 similar to the above is used, but does not reach down completely over the spring coil section 12. For instance, the overlay may reach 3″ down from the top surface of the spring coil section. In this case the zipper 40 may be placed about 2″ down from the top surface 13 of the spring coil section, in order to provide about 1″ of overlay 50 over the zipper 40 to protect the zipper and users from snagging the zipper.

It will be understood by one having ordinary skill in the art that construction of the described disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement of the elements of the disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise. 

What is claimed is:
 1. A modular mattress comprising: a spring coil assembly comprising: a plurality of spring coils having a spring wrapped in a thin fabric and arranged in a generally rectangular shape; a first sturdy fabric exterior surrounding the plurality of spring coils; a first connection element; and a padding assembly comprising: a polyurethane foam in a generally rectangular shape corresponding to the shape and size of the spring coil assembly; a second sturdy fabric exterior surrounding the polyurethane foam; a second connection element; wherein the first connection element and the second connection element are configured to couple the spring coil assembly and the padding assembly.
 2. The modular mattress of claim 1, wherein the first connection element is a first portion of a zipper, and the second connection element is a second portion of a zipper.
 3. The modular mattress of claim 2, wherein the first zipper portion is on a top surface of the spring coil assembly, and the second zipper portion is on a bottom surface of the padding assembly.
 4. The modular mattress of claim 3, wherein the first and second zipper portions are inset from the perimeter of the modular mattress.
 5. The modular mattress of claim 1, wherein the padding assembly further comprises an overlay that covers a head, foot, right, and left sides of the spring coil assembly.
 6. The modular mattress of claim 5, wherein the first and second connection elements are on a bottom surface of the spring coil assembly.
 7. The modular mattress of claim 1, wherein the first and second connection elements are selected from the following: hook and loop connection, toggles, snaps, and straps and buckles.
 8. A modular mattress comprising: a spring coil assembly having a generally rectangular shape and including plurality of spring coils surrounded by a fabric exterior; and a padding assembly corresponding to the shape and size of the spring coil assembly and including a sturdy fabric exterior surrounding a polyurethane foam; wherein the spring coil assembly and the padding assembly are removably coupled together by a first connection element on the spring coil assembly and a second connection element on the padding assembly.
 9. The modular mattress of claim 8, wherein the first connection element is a first portion of a zipper, and the second connection element is a second portion of a zipper.
 10. The modular mattress of claim 9, wherein the first zipper portion is on a top surface of the spring coil assembly, and the second zipper portion is on a bottom surface of the padding assembly.
 11. The modular mattress of claim 10, wherein the first and second zipper portions are inset from the perimeter of the modular mattress.
 12. The modular mattress of claim 8, wherein the padding assembly further comprises an overlay that covers a head, foot, right, and left sides of the spring coil assembly.
 13. The modular mattress of claim 12, wherein the first and second connection elements are on a bottom surface of the spring coil assembly.
 14. The modular mattress of claim 8, wherein the first and second connection elements are selected from the following: hook and loop connection, toggles, snaps, and straps and buckles.
 15. A modular mattress comprising: a spring coil assembly comprising: a plurality of spring coils having a spring wrapped in a thin fabric and arranged in a generally rectangular shape; a first sturdy fabric exterior surrounding the plurality of spring coils; a first connection element sewn to the first sturdy fabric exterior; and a padding assembly comprising: a polyurethane foam in a generally rectangular shape corresponding to the shape and size of the spring coil assembly; a second sturdy fabric exterior surrounding the polyurethane foam; a second connection element sewn to the second sturdy fabric exterior; wherein the first connection element and the second connection element are configured to removably couple the spring coil assembly and the padding assembly.
 16. The modular mattress of claim 15, wherein the first connection element is a first portion of a zipper attached to a top side of the spring coil assembly, and the second connection element is a second portion of a zipper attached to a bottom side of the padding assembly.
 17. The modular mattress of claim 16, wherein the first and second zipper portions are inset from the perimeter of the modular mattress.
 18. The modular mattress of claim 15, wherein the padding assembly further comprises an overlay that covers a head, foot, right, and left sides of the spring coil assembly.
 19. The modular mattress of claim 18, wherein the first connection element is on a bottom surface of the spring coil assembly and the second connection element is on an end of the overlay.
 20. The modular mattress of claim 15, wherein the first and second connection elements are selected from the following: hook and loop connection, toggles, snaps, and straps and buckles. 